Large scale smart susceptor heater blankets requiring multi zone control

ABSTRACT

A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.

CROSS REFERENCE

This application is a divisional of U.S. patent application Ser. No.15/056,297 filed Feb. 29, 2017, which issued on Jul. 22, 2019 as U.S.Pat. No. 10,336,013, the disclosure of which is hereby incorporatedherein by reference in its entirety.

TECHNICAL FIELD

The present teachings relate to the manufacture of laminated compositematerials that include a debulk of an uncured composite laminate toform, for example, a component for an aircraft, aerospace vehicle, orother vehicle.

BACKGROUND

Manufacturing components for vehicles such as aircraft and aerospacevehicles, ground vehicles, etc., from fiber sheets is well known. Acomposite part including a plurality of composite plies or sheets thatare pre-impregnated with an uncured resin (i.e., prepregs) may beassembled during a layup process. During layup, several (i.e., 20, 40,or more) uncured composite plies are stacked, and then air that may betrapped between each of the several plies may be removed using a vacuumduring a “debulk” process. Subsequently, the resin may be cured in anoven or an autoclave. During the curing of the resin, the component issupported on a cure tool that maintains the shape of the component whileheat is applied to the component to cure the resin.

The debulking and curing of the plurality of composite plies may beperformed in an autoclave. Additionally, techniques have been developedfor debulking composite parts without the need for an oven or autoclave.For example, a plurality of uncured composite plies may be placed into avacuum bag and heated to a temperature below the cure temperature. Avacuum is applied to the vacuum bag to remove air from between eachadjacent ply. The debulked composite part may then be removed from thevacuum bag and processed such that it is ready to be heated to a curetemperature within an autoclave.

Debulking of components through the application of heat within a vacuumbag is convenient and cost effective for smaller parts. A relativelysmall heater blanket may be manufactured at reasonable cost and used todebulk smaller components. However, this approach may not be suitablefor some components such as aircraft components (e.g., horizontalstabilizers) which may be manufactured as a large single seamlessstructure.

Accordingly, there is a need for a method and apparatus for OOAdebulking of composite parts out-of-autoclave that employ relativelysimple and inexpensive cure tooling. There is also a need for a methodand apparatus of the type mentioned above that is well suited forprocessing relatively large scale parts out-of-autoclave using inductionheating and smart susceptors to provide precise and uniform temperaturecontrol during the debulk process.

SUMMARY

The following presents a simplified summary in order to provide a basicunderstanding of some aspects of one or more embodiments of the presentteachings. This summary is not an extensive overview, nor is it intendedto identify key or critical elements of the present teachings, nor todelineate the scope of the disclosure. Rather, its primary purpose ismerely to present one or more concepts in simplified form as a preludeto the detailed description presented later.

In an implementation of the present teachings, a method for processingan article through an application of heat includes positioning a firstsmart susceptor heater blanket having a first wire ribbon adjacent to asecond smart susceptor heater blanket including a second wire ribbon,placing a plurality of uncured composite plies in proximity to the firstsmart susceptor heater blanket and the second smart susceptor heaterblanket, and applying a current to a plurality of first wire assembliesof the first wire ribbon, wherein each first wire assembly is adjacentto at least one other first wire assembly, such that a current flowthrough each first wire assembly is in a direction that is opposite to acurrent flow through any adjacent first wire assembly. The methodfurther includes applying a current to a plurality of second wireassemblies of the second wire ribbon such that a current flow througheach second wire assembly is in a direction that is opposite to acurrent flow through any adjacent second wire assembly, wherein eachsecond wire assembly is adjacent to at least one other second wireassembly and the positioning further includes placing the first smartsusceptor heater blanket adjacent to one of the second wire assembliessuch that the current flow through the first wire assembly adjacent tothe second wire assembly is in a direction that is opposite to thecurrent flow through the adjacent second wire assembly.

Optionally, the applying of the current to the plurality of first wireassemblies and the applying of the current to the plurality of secondwire assemblies applies the current in series between the first smartsusceptor heater blanket and the second smart susceptor heater blanket.The applying of the current to the plurality of first wire assembliesand the applying of the current to the plurality of second wireassemblies can apply the current in parallel between the first smartsusceptor heater blanket and the second smart susceptor heater blanket.

The method can further include applying the current flow to theplurality of first wire assemblies using a first power supply andapplying the current flow to the plurality of second wire assembliesusing a second power supply. Optionally, the method can further includeregulating the current flow to the first smart susceptor heater blanketusing a controller and regulating the current flow to the second smartsusceptor heater blanket using the controller, and can also includemonitoring a plurality of temperatures at a plurality of locations ofthe first smart susceptor heater blanket using a first plurality ofthermal sensors distributed across the first smart susceptor heaterblanket, regulating the current flow output by the first power supply tothe first smart susceptor heater blanket based on an output receivedfrom the first plurality of thermal sensors using the controller,monitoring a plurality of temperatures at a plurality of locations ofthe second smart susceptor heater blanket using a second plurality ofthermal sensors distributed across the second smart susceptor heaterblanket, and regulating the current flow output by the second powersupply to the second smart susceptor heater blanket based on an outputreceived from the second plurality of thermal sensors using thecontroller

Further optionally, the method can include transmitting an output from afirst plurality of thermal sensors distributed across the first smartsusceptor heater blanket to a controller, transmitting an output from asecond plurality of thermal sensors distributed across the second smartsusceptor heater blanket to the controller, regulating the current flowto the second smart susceptor heater blanket based on the output fromthe first plurality of thermal sensors using the controller, andregulating the current flow to the first smart susceptor heater blanketbased on the output from the second plurality of thermal sensors usingthe controller. The controller can be a master controller and the methodcan further include controlling a first slave controller using themaster controller to perform the regulating of the current flow to thefirst smart susceptor heater blanket and controlling a second slavecontroller using the master controller to perform the regulating of thecurrent flow to the second smart susceptor heater blanket.

Some implementations can also include placing a plurality of compositeplies into a vacuum bag, wherein the plurality of composite plies arepre-impregnated with an uncured resin, placing the vacuum bag and theplurality of composite plies in proximity to the first smart susceptorheater blanket and the second smart susceptor heater blanket, andheating the plurality of composite plies using the first smart susceptorheater blanket and the second smart susceptor heater blanket.Optionally, the method can further include applying a vacuum to thevacuum bag and to the plurality of composite plies during the heating todebulk the plurality of composite plies.

In another implementation, a method for debulking an aircraft componentincludes positioning an uncured composite laminate having a plurality ofprepregs onto a layup mandrel, positioning a heater blanket assemblyadjacent to the uncured composite laminate, wherein the heater blanketassembly includes a first smart susceptor heater blanket having a firstwire ribbon adjacent to a second smart susceptor heater blanketincluding a second wire ribbon, applying a current to a plurality offirst wire assemblies of the first wire ribbon, wherein each first wireassembly is adjacent to at least one other first wire assembly, suchthat a current flow through each first wire assembly is in a directionthat is opposite to a current flow through any other adjacent first wireassembly, applying a current to a plurality of second wire assemblies ofthe second wire ribbon such that a current flow through each second wireassembly is in a direction that is opposite to a current flow throughany other adjacent second wire assembly, wherein each second wireassembly is adjacent to at least one other second wire assembly, one ofthe second wire assemblies is adjacent to one of the first wireassemblies, and a current flow through the second wire assembly adjacentto the first wire assembly is in a direction that is opposite to thecurrent flow through the adjacent first wire assembly, and heating theuncured composite laminate using the heater blanket assembly.

Optionally, the method can further include applying a vacuum to theuncured composite laminate during the heating of the uncured compositelaminate. An implementation can also include heating the uncuredcomposite laminate to a temperature that is below a cure temperature ofthe uncured composite laminate during the applying of the vacuum to theuncured composite laminate, thereby debulking the uncured compositelaminate and removing the debulked uncured composite laminate from thelayup mandrel prior to the uncured composite laminate reaching a curetemperature of the uncured composite laminate. Some implementations canalso include applying the current flow to the plurality of first wireassemblies using a first power supply and applying the current flow tothe plurality of second wire assemblies using a second power supply.Optionally, the method can further include regulating the current flowto the first smart susceptor heater blanket using a controller andregulating the current flow to the second smart susceptor heater blanketusing the controller, and may include monitoring a plurality oftemperatures at a plurality of locations of the first smart susceptorheater blanket using a first plurality of thermal sensors distributedacross the first smart susceptor heater blanket, regulating the currentflow output by the first power supply to the first smart susceptorheater blanket based on an output received from the first plurality ofthermal sensors using the controller, monitoring a plurality oftemperatures at a plurality of locations of the second smart susceptorheater blanket using a second plurality of thermal sensors distributedacross the second smart susceptor heater blanket, and regulating thecurrent flow output by the second power supply to the second smartsusceptor heater blanket based on an output received from the secondplurality of thermal sensors using the controller.

Further optionally, the method can include transmitting an output from afirst plurality of thermal sensors distributed across the first smartsusceptor heater blanket to a controller, transmitting an output from asecond plurality of thermal sensors distributed across the second smartsusceptor heater blanket to the controller, regulating the current flowto the second smart susceptor heater blanket based on the output fromthe first plurality of thermal sensors using the controller, andregulating the current flow to the first smart susceptor heater blanketbased on the output from the second plurality of thermal sensors usingthe controller. The controller can be a master controller and the methodcan further include controlling a first slave controller using themaster controller to perform the regulating of the current flow to thefirst smart susceptor heater blanket and controlling a second slavecontroller using the master controller to perform the regulating of thecurrent flow to the second smart susceptor heater blanket.

Some implementations of the method can further include placing theuncured composite laminate into a vacuum bag, placing the vacuum bag andthe uncured composite laminate onto the layup mandrel, and heating thevacuum bag and the uncured composite laminate using the first smartsusceptor heater blanket and the second smart susceptor heater blanket.Optionally, the method can further include applying a vacuum to thevacuum bag and to the uncured composite laminate during the heating todebulk the uncured composite laminate.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in, and constitute apart of this specification, illustrate embodiments of the presentteachings and, together with the description, serve to explain theprinciples of the disclosure. In the figures:

FIG. 1 is a perspective depiction of a wire assembly including a litzwire and a susceptor wire in accordance with an embodiment of thepresent teachings;

FIG. 2 is a perspective depiction of a wire ribbon including a pluralityof wire assemblies in accordance with an embodiment of the presentteachings;

FIG. 3 is a plan view of a smart susceptor heater blanket in accordancewith an embodiment of the present teachings;

FIG. 4 is a plan view depicting two or more adjacent smart susceptorheater blankets in accordance with an embodiment of the presentteachings;

FIG. 5 is a schematic depiction of a processing assembly such as adebulking apparatus in accordance with an embodiment of the presentteachings;

FIG. 6 is a schematic plan view depicting a portion of a smart susceptorheater blanket in accordance with an embodiment of the presentteachings;

FIG. 7 is a schematic plan view depicting two or more smart susceptorheater blankets to be connected in series in accordance with anembodiment of the present teachings;

FIG. 8 is a schematic plan view depicting two or more smart susceptorheater blankets to be connected in parallel in accordance with anembodiment of the present teachings;

FIG. 9 is a plan view depicting a plurality of smart susceptor heaterblankets and an uncured composite part to be debulked in accordance withan embodiment of the present teachings;

FIG. 10 is a cross section depicting a plurality of smart susceptorheater blankets and an uncured composite part to be debulked inaccordance with an embodiment of the present teachings;

FIG. 11 is a flow chart of a method according to an embodiment of thepresent teachings; and

FIG. 12 is a side view of an aircraft including one or more compositeparts formed using an embodiment of the present teachings.

It should be noted that some details of the FIGS. have been simplifiedand are drawn to facilitate understanding of the present teachingsrather than to maintain strict structural accuracy, detail, and scale.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of thepresent teachings, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same or like parts.

A smart susceptor heater blanket (hereinafter, “heater blanket”) forout-of-autoclave (OOA) curing of a composite patch is described, forexample, in U.S. Pat. No. 9,174,398 which is commonly assigned herewithand incorporated herein by reference in its entirety. The heater blanketof the incorporated patent may be used to cure a patch over a relativelysmall rework area.

An embodiment of the present teachings may provide a method andapparatus for processing large components OOA, for example, debulking ofan uncured composite part. The method and apparatus may allow OOAdebulking of a large-scale composite part, for example, a plurality ofuncured composite plies having a size (e.g., a perimeter, footprint, oroutside dimension) that previously required debulking or otherprocessing within an autoclave due to size or other contributingfactors. With prior processing, increasing the blanket size toaccommodate large-scale composite parts presents several challenges. Forexample, a large heater blankets require long internal wiring with ahigh electrical resistance, and therefore require a high current powersource to sufficiently power the blanket, which is expensive. Further,very large smart susceptor heater blankets are expensive to manufacture,and the cost of scrapping an unrepairable smart susceptor heater blanketis also expensive. Therefore, large components have most often been bothdebulked and cured within an autoclave. However, autoclave processing isalso expensive as a large volume of process gas such as nitrogen must beheated, cooled, and reheated during debulking of a large-scale compositepart within an autoclave. There is also substantial capital cost andmanufacturing flow time associated with the use of an autoclave.

An embodiment of the present teachings may include processing apparatusincluding a plurality of interconnected heater blankets. While thepresent teachings are generally described with reference to a debulkingprocess for simplicity, it will be understood that other processing,such as curing, is also contemplated.

The debulking apparatus may include a particular electrical design thatrequires a relatively low current power source and has a low electricalinterference between adjacent heater blankets. In an embodiment, thedebulking apparatus may include at least two (i.e., two or more) heaterblankets, for example, 8, 12, 16, 20, or more interconnected heaterblankets, with the number of interconnected heater blankets depending,for example, on the size of the heater blankets and the size of thecomposite part that is being debulked. A modular heater blanket designin accordance with an embodiment of the present teachings may facilitatesimplified replacement and powering of apparatus components at a reducedcost compared to single heater blanket designs.

It will be appreciated that actual assemblies represented by the FIGS.may include other structures that have not been depicted for simplicity,and that depicted structures may be removed or modified.

FIG. 1 is a perspective depiction of a portion of a heater blanket wireassembly 100 that includes a litz wire 102 and a susceptor wire 104 thatmay wrap around the litz wire 102 in a helix or spiral to form aplurality of susceptor windings around the litz wire. As known in theart, the litz wire 102 includes a plurality of electrically conductivewires 106 electrically insulated from each other, and an electricalinsulator 108 interposed between the susceptor wire 104 and theplurality of conductive wires 106. In an embodiment, the wire assembly100 may have a diameter of from about 0.04″ to about 0.08″, or about0.06″, as measured on an outside surface of the susceptor wire 104,although other dimensions are contemplated. The wire assembly 100includes a first end and a second end opposite the first end, whereinthe wire assembly 100 extends from the first end to the second end. Thelength of the wire assembly 100 will depend on the size of the heaterblanket that it forms a part of but, in an embodiment, the wire assembly100 may be from about 5 feet to about 100 feet long.

FIG. 2 is a cutaway perspective depiction of a portion of a wire ribbon200 that includes a plurality of individual spaced wire assemblies 100.The plurality of wire assemblies 100 may be encapsulated or otherwiseencased together within an electrically insulative and thermallyconductive binder 202 such as a silicone binder. In an embodiment, thebinder 202 may have a thickness of from about 0.025″ to about 0.25″, oranother thickness that is suitable for transfer of thermal energygenerated within the susceptor wires by the flow of current through thelitz wires to an adjacent workpiece. The wire ribbon 200 may include anynumber of wire assemblies 100, for example, at least two, or up to 10 ormore wire assemblies 100. The wire ribbon 200 may have a width of fromabout 0.5″ to about 12″, or from about 0.5″ to about 12″, or from about2″ to about 12″, or from about 0.5″ to about 6.0″, or another suitablewidth depending, for example, on size constraints, electricalconstraints, the number of wire assemblies 100 within the wire ribbon200, etc.

FIG. 3 is a plan view depicting a heater blanket 300 including the wireribbon 200 of FIG. 2. For illustration, the wire ribbon 200 of FIG. 3includes four wire assemblies 100A-100D. The heater blanket 300 mayinclude a blanket substrate 302. In an embodiment, the blanket substrate302 may include a layer of silicone binder to which the wire ribbon isattached using an attachment such as an adhesive. In another embodiment,the blanket substrate 302 may include two layers of silicone binder,wherein the wire ribbon 200 is interposed between the two layers. In anycase, the wire ribbon is positioned to extend back and forth (i.e.,serpentine) across the heater blanket as depicted in FIG. 3. While thewire ribbon 200 in FIG. 3 is depicted with three 180° turns forsimplicity given the scale of the figure, it will be appreciated that awire ribbon 200 may include, for example, between six and twelve 180°turns, or eight or more 180° turns as it serpentines across the heaterblanket 300. Further, the wire ribbon 200 may be formed as a straightribbon and folded in a desired pattern to form the heater blanket 300,and may extend across the heater blanket 300 in other patterns. Ingeneral, the wire ribbon 200 may cover a suitable percentage of theheater blanket surface area, perimeter, or footprint to maintain evenheating of the article being debulked during the debulking process.

The heater blanket 300 further includes a first electrical connector 304attached to the first end of each wire assembly 100 and a secondelectrical connector 306 attached to the second end of each wireassembly. In an embodiment, the first electrical connector 304 may be amale type connector and the second electrical connector may be a femaletype connector. The pair of connectors 304, 306 allows a power source tobe electrically coupled to each of the wire assemblies 100A-100D usingeither a series connection or a parallel connection as described below.Two or more heater blankets 300 may be manufactured.

Two or more heater blankets 300 of FIG. 3 may be assembled to form acomponent of the debulking apparatus as depicted in FIG. 4, whichdepicts a first heater blanket 300 and a second heater blanket 300 prime(300′), which may be identical or may vary in shape. However, ingeneral, the length of the wire ribbon 200 within each heater blanketmay be similar such that both or all heater blankets are matched withrespect to power requirements. In an embodiment, the wire ribbon 200within each heater blanket 300 may be manufactured such that the lengthof all wire ribbons varies by no more than about ±10% from a targetlength. In other words, the shortest wire ribbon may have a length nomore than 0.9 times the target length of all wire ribbons for thedebulking apparatus, and the longest wire ribbon may have a length nomore than 1.1 times the target length. This ensures that all heaterblankets within the debulking apparatus operate with similar heating andcooling characteristics so that a uniform and predictable temperaturemay be maintained across the article being debulked. In otherembodiments, the wire ribbon 200 within each heater blanket 300 may bemanufactured such that the length of all wire ribbons varies by no morethan ±20%, or by no more than ±15%. In other embodiments, the variationin length may not a design consideration.

FIG. 5 is a block diagram of a heater blanket apparatus 500 that may bepart of a debulking apparatus. While the FIG. 5 depiction includes twoheater blankets 300, 300′ for debulking an uncured composite part inaccordance with an embodiment of the present teachings, it will beunderstood that a heater blanket apparatus 500 may include any number ofheater blankets. FIG. 5 depicts one or more power supplies 502, 502′including an input 504 and an output 506. As described below, one powersupply 502 may power all heater blankets 300, 300′, or separate powersupplies 502, 502′ may power each heater blanket 300, 300′. FIG. 5further depicts a junction box 508 having an input (e.g., the output 506of the power supply 502). The junction box provides a first input/output510 to each of the first connectors 304, and a second input/output toeach of the second connectors 306. The input/outputs 510, 512 from thejunction box 508 will depend on the particular design or configurationof the heater blanket apparatus 500 as described below. The heaterblankets 300, 300′ are electrically coupled with, and receive powerthrough, input/outputs 510, 512 of the junction box 508 through theelectrical connectors 304, 306 as depicted.

FIG. 5 further depicts a plurality of thermal sensors 514 such asthermocouples. The thermal sensors 514 are in thermal communication 516with one or more of the heater blankets 300, 300′. In an embodiment, aplurality of the thermal sensors are in thermal proximity to each of theheater blankets 300, 300′ to monitor a temperature of the heaterblankets 300, 300′, and assist in maintaining a uniform heater blankettemperature range during debulking. The thermal sensors 514 may transfertemperature data to a controller 518, for example, through a wired orwireless connection or interface 520. The controller 518 is inelectrical communication with, and controls, the power supply through,for example, a communication cable 522.

The master controller 518 may be electrically coupled with, and control,a plurality of slave controllers 524, 524′. Each slave controller 524,524′ is electrically coupled with one of the heater blankets 300, 300′respectively. Each slave controller 524, 524′ monitors and controls oneof the heater blankets 300, 300′. Further, each slave controller 524,524′ may receive data and instructions from the master controller 518,and may pass operational data relative to the heater blankets 300, 300′to the master controller 518. The master controller 518 may control theoutput 506 from the power supplies 502, 502′ based on the heater blanketoperational data.

During use, each litz wire 102 of each wire ribbon 200 is electricallycoupled with the power supply 502. Current from the power supply 502flowing through the litz wire 102 generates a magnetic field within eachsusceptor wire 104 of each wire ribbon 200 of each heater blanket 300.The magnetic field, in turn, generates heat within the wire ribbon 200which thereby heats each heater blanket 300. The susceptor wire includesa Curie temperature (Tc), where the Curie temperature results, at leastin part, from the particular composition of the susceptor wire.Inductive heating of the susceptor wire may be reduced when thesusceptor sleeve becomes non-magnetic upon reaching the Curietemperature. The reduction in the heating of the susceptor sleeve mayresult in reducing the conductive heating of the structure. At a lowtemperature, a magnetic permeability of the susceptor wire 104 is high,and thus a skin depth of the susceptor wire 104 is small and themagnetic field induces strong eddy currents having a relatively highthermal output that heats the heater blanket 300. As the temperature ofthe susceptor wire 104 increases, the magnetic permeability of thesusceptor wire 104 decreases to a lower value and the skin depth of thesusceptor wire 104 increases. At high temperatures, the skin depth islarger than the radius of the susceptor wire 104, and the eddy currentswithin the susceptor wire 104 interfere with each other therebyweakening the eddy currents. The weaker eddy currents have a relativelylow thermal output and thus the heater blanket 300 generates less heat.Each portion of the susceptor wire 104 thereby becomes its owntemperature regulator to maintain a uniform temperature without alteringthe current applied to the litz wire 102. The temperatureself-regulation occurs locally and continuously along the length of eachwire ribbon 200, such that the desired temperature within a temperaturerange is maintained at all locations along the length of the wire ribbon200 and, therefore, across the area of the heater blanket 300. Unlessotherwise noted, as used herein, the terms “smart susceptor heaterblanket,” “susceptor heater blanket,” and “heater blanket” refer to aheater blanket that is capable of temperature self-regulation.

As depicted in FIG. 4, at least two heater blankets 300, 300′ are placedadjacent to each other during a debulking operation, for example, toincrease the area that may be simultaneously debulked. The two or moreheater blankets 300, 300′ may be electrically coupled together, eitherin series or in parallel, and to the power supply 502 as describedbelow.

The arrows positioned near each connector 304, 306 on each wire assembly100 of FIG. 4 represent a direction of AC current flow at a given pointin time that provides a current polarity for each wire assembly 100 and,more particularly, through each litz wire 102 of each wire assembly 100.The current is applied to each litz wire 102 such that the current flowsin a direction that is opposite to the direction of current flow throughevery adjacent litz wire 102. In other words, during use, the current ineach wire segment is 180° out of phase with each adjacent wire segment.As depicted in FIG. 4, current flows away from the first connector 304and toward the second connector 306 for wire assemblies 100A and 100C,and current flows toward the first connector 304 and away from thesecond connector 306 for wire assemblies 1006 and 100D. In other words,current flows in a first direction for wire assemblies 100A and 100C(generally depicted as relatively longer dashed lines) and in a seconddirection for their respective adjacent wire assemblies 1006 and 100D(generally depicted as relatively shorter dashed lines), wherein thesecond direction is opposite to the first direction.

Additionally, as depicted in FIG. 4, for purposes of description, eachwire ribbon 200, 200′ may include a plurality of parallel major segmentsor legs 400, 400′ that are positioned adjacent to at least one othermajor segment 400, 400′. As depicted, the rightmost major segment 400for heater blanket 300 is positioned adjacent to, and is parallel with,the leftmost major segment 400′ for heater blanket 300′, such that wireassembly 100A is positioned adjacent to wire assembly 100A′. Asdepicted, the flow of current through wire assembly 100A in therightmost major segment 400 is opposite to the flow of current throughwire assembly 100A′ in the leftmost major segment 400′. It will berealized, however, that this occurs particularly when both blankets areconnected to the same power supply. In general, two or more powersupplies will operate at somewhat different frequencies and so, in thisexample, current in the rightmost major segment 400 will be in theopposite direction only about half the time. This will lead to at leasta small increase in magnetic fields.

Maintaining the flow of current in opposite directions for all adjacentwire assemblies 100A-100D, 100A′-100D′ ensures that any magnetic fieldnot absorbed by the susceptor windings is minimized by cancellation ofan opposing field generated by the two adjacent major segments 400. Thisspecific design element of the individual smart susceptor heaterblankets 300, at least in part, enables the ability to place two or moreheater blankets 300 directly adjacent to one another without causing orresulting in electromagnetic or thermal interference which would affectthe heating of the heater blanket 300, the debulking apparatus ingeneral, and any item being heated thereby.

Various connection configurations for electrically coupling each heaterblanket with the power supply and/or the junction box are contemplated.In one embodiment as depicted in FIG. 6, a pair of connector types maybe used at each end of the wire ribbon 200. In this embodiment, the litzwires having the same polarity (e.g., the same current flow direction)are grouped into the same connector to enable proper electricalconnection to adjacent blankets or electrical coupling to the powersupply. In FIG. 6, connector 600 is a female connector having a negativepolarity (i.e., current flow toward the connector) that is connected toa first end of wire assemblies 1006 and 100D, connector 602 is a maleconnector having a positive polarity (i.e., current flow away from theconnector) that is connected to a second end of wire assemblies 100B and100D, connector 604 is a female connector having a negative polaritythat is connected to a first end of wire assemblies 100A and 100C, andconnector 606 is a male connector having a positive polarity that isconnected to a second end of wire assemblies 100A and 100C.

FIG. 7 depicts the heater blanket 300 (e.g., a first heater blanket) ofFIG. 6 as it may be electrically coupled with a second heater blanket300′ using a series electrical connection (i.e., in series). Connectors600, 606 of the first heater blanket 300 and connectors 602′, 604′ ofthe second heater blanket 300′ are electrically connected or coupledwith the power supply 502 and/or junction box 508, for example throughelectrical connectors as depicted. Connectors 602, 604 of the firstheater blanket 300 are electrically connected to connectors 600′, 606′of the second heater blanket 300′ as depicted.

FIG. 8 depicts the first heater blanket 300 as it may be electricallycoupled with the second heater blanket 300′ using a parallel electricalconnection (i.e., in parallel). Each of the electrical connectors600-606, 600′-606′ are electrically connected or coupled with the powersupply 502 and/or junction box 508, for example through electricalconnectors as depicted. In an embodiment, each power supply 502 of FIG.8 is the same power supply 502. In another embodiment, each power supply502 of FIG. 8 is a different power supply 502, for example, to reducethe current requirements for each power supply.

FIG. 9 is a plan view, and FIG. 10 is a cross section, of a debulkingassembly including a plurality of heater blankets 300A-300P during use,and an uncured composite part or article 900 to be debulked. In thisembodiment, 16 heater blankets (e.g., corresponding to 16 heating zones)300A-300P are placed adjacent to each other and electrically coupled toa power supply, for example, as described above or using anotherconnection design. In an embodiment, each heater blanket 300A-300P maybe attached to a different power supply as described above, for example,to reduce current requirements. While FIG. 10 depicts the heaterblankets 300A-300P overlying the composite part 900, the composite part900 may be placed over the heater blankets 300A-300P. It will berealized that heater blankets may also be placed both over and under thecomposite part 900 during debulking. Further, while the composite part900 of FIG. 10 depicts four laminate layers 900A-900D such as prepregs,it will be appreciated that the composite part 900 may include anynumber of laminate layers to be laminated together, for example, 40 ormore layers. Further, composite part 900 may include a three dimensional(3D) woven prepreg rather than a laminate.

In FIG. 9, the plurality of heater blankets 300A-300P includeindividualized shapes that are designed to conform to the shape of thecomposite part 900 being debulked. Each heater blanket of the pluralityof heater blankets 300A-300P may have the same, or different, perimeterlengths and shapes as all other heater blankets 300A-300P. Some heaterblankets of the plurality of heater blankets 300A-300P may have the sameperimeter lengths and shapes as other heater blankets 300A-300P, whileother heater blankets have different perimeter shapes and lengths asother heater blankets 300A-300P. In an embodiment, each heater blanket300A-300P may have a wire ribbon 200 as described above. In anembodiment including only a single power supply that powers every heaterblanket 300A-300P, each wire ribbon for each heater blanket 300A-300Pmay be designed to have a length that varies no more than ±20%, or nomore than ±15%, or no more than ±10% from a common target value, suchthat the power requirements for each heater blanket 300A-300P arematched and similar to all other heater blankets 300A-300P. Theplurality of heater blankets 300A-300P may be mechanically attached to amounting surface or support 1000 using, for example, a plurality offasteners 1002 (depicted only on heater blanket 300E in FIG. 10 forsimplicity). The fasteners 1002 may maintain the each blanket in a fixedposition relative to one or more adjacent blankets. The composite part900 may rest on a base or working surface 1004, such as a contouredlayup mandrel, during debulking. In an embodiment where each heaterblanket 300A-300P is powered by a separate power supply, the output ofall power supplies may be the same, or the output may be matched for therequirement of the heater blanket that it powers.

In an embodiment, the composite part 900 may be placed into a vacuum bag1006 that is attached to a vacuum source 1008 during debulking. During adebulking operation, electrical power is applied to each of the heaterblankets 300A-300P while a vacuum is applied to the vacuum bag 1006 bythe vacuum source 1008. The heater blankets 300A-300P may be designed toreach and maintain a target temperature such that the requirements fordebulking the composite part 900 are met, and thus heat the compositepart 900 to a desired temperature. The smart susceptor effect provideslocalized temperature control to account for variations in thermal load.

In an embodiment, each of the 16 heater blankets may be controlledthrough the use of 16 slave controllers 524 (FIG. 5), wherein each slavecontroller 524 controls and monitors one of the heater blankets300A-300P. In an embodiment, the master controller 518 (FIG. 5) maydefine a ramp of temperature of each heater blanket 300A-300P, eitherdirectly or through the slave controllers 524, until each heater blanket300A-300P reaches a temperature target or set point. The 16 slavecontrollers power the 16 heater blankets via feedback control loop basedon temperature values within each zone measured, for example, usingthermal sensors 514. Software within the controller 518 may include asoftware algorithm that surveys multiple temperatures in each zone. Thehighest temperature from a plurality of measurement points may be usedfor control at every point in time. The highest temperature during thetemperature ramp may change from location to location within a zone overthe duration of the temperature ramp and/or temperature dwell.

Each of the one or more power supplies may include load tuning that maybe used to monitor a health of each smart susceptor heater blanket300A-300P. The master controller 518 and/or slave controllers 524 maymonitor the health of each heater blanket 300A-300P, both prior to andduring the debulking operation. The controller 518 may further monitoroperation of the vacuum source 1008 and the vacuum within the vacuum bag1006. Process data may be continuously captured and logged within a datafile before, during, and after a debulking operation for real-time orsubsequent analysis.

It will be appreciated that the plurality of heater blankets 300A-300Pmay be assembled into an enclosure or interposed between two or morerigid and/or flexible layers such that the plurality of modular heaterblankets 300A-300P become subassemblies of a heater blanket assembly.

FIG. 11 is a flow chart depicting a method 1100 for processing anarticle through the application of heat. The method can includepositioning a first smart susceptor heater blanket having a first wireribbon adjacent to a second smart susceptor heater blanket including asecond wire ribbon as depicted at 1102. Next, a plurality of uncuredcomposite plies may be placed in proximity to the first smart susceptorheater blanket and the second smart susceptor heater blanket as depictedat 1104. A current may be applied to a plurality of first wireassemblies of the first wire ribbon as depicted at 1106. In anembodiment, each first wire assembly may be adjacent to at least oneother first wire assembly such that a current flow through each firstwire assembly is in a direction that is opposite to a current flowthrough any adjacent first wire assembly. Additionally, a current may beapplied to a plurality of second wire assemblies of the second wireribbon such that a current flow through each second wire assembly is ina direction that is opposite to a current flow through any adjacentsecond wire assembly as depicted at 1108. In an embodiment of the FIG.11 method, each second wire assembly may be adjacent to at least oneother second wire assembly. Further, the positioning may further includeplacing the first smart susceptor heater blanket adjacent to one of thesecond wire assemblies such that the current flow through the first wireassembly adjacent to the second wire assembly is in a direction that isopposite to the current flow through the adjacent second wire assembly.

It will be appreciated that, one or more of the acts depicted herein,for example, in FIG. 11, may be carried out in one or more separate actsand/or phases, and/or in a different order than that depicted.

The apparatus described herein may be used for debulking of a compositepart or for other processing operations. For example, FIG. 12 depicts anaircraft 1200 that includes composite parts that may be debulked orotherwise processed using an embodiment of the present teachings. In oneparticular used, a horizontal stabilizer 1202, a vertical stabilizer1204, and/or other aircraft structures may be processed as describedabove.

The design of the individual smart susceptor heater blankets thusenables the ability to place the heater blankets directly adjacent toone another without causing electromagnetic or thermal interferencebetween heater blankets. Within each wire ribbon, and in the outermostconductors of adjacent wire ribbons, the currents in any two adjacentconductors will, in general, always travel in opposing directions. Thisensures that any magnetic field not absorbed by the susceptor windingsis minimized by cancellation of an opposing field generated by the twoadjacent wires. Other embodiments are contemplated, for example, wherethe conductors at blanket edges are powered by different power supplies.In general, the heater blankets are relatively large and contain manyconductors and so any interference between the outermost conductors onadjacent blankets will be manageably small.

The use of several interconnected heater blankets further allows fordebulking or other processing of larger workpieces outside of anautoclave than was previously practical using a single large heaterblanket. Damage to a large heater blanket results in the replacement ofthe entire heater blanket. If damage occurs to one of the heaterblankets of the assembly described herein, the modular design using aplurality of heater blankets results in the replacement of only one ofthe subunits. Further, the high current and voltage needed to drive aplurality of litz wires within single large blanket is expensive andhazardous to manufacturing personnel. Powering multiple heater blanketsusing multiple power supplies allows for use of lower current andvoltages, which improve safety for manufacturing personnel.

It will be appreciated that the structures described herein as a vacuumbag may be, in some embodiments, a vacuum bag such as a disposablevacuum bag or single-use vacuum bag that provides a vacuum chamber intowhich the workpiece is inserted and then sealed within during adebulking process (see, for example, the vacuum bag 1106 of FIG. 10). Inother embodiments, a vacuum bag may be a vacuum membrane such as asingle sheet, or two or more laminated sheets, of pliable material that,together with another structure such as the layup mandrel, form anenclosed and sealed vacuum chamber that is used to provide a vacuumaround the workpiece.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the present teachings are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard deviation foundin their respective testing measurements. Moreover, all ranges disclosedherein are to be understood to encompass any and all sub-ranges subsumedtherein. For example, a range of “less than 10” can include any and allsub-ranges between (and including) the minimum value of zero and themaximum value of 10, that is, any and all sub-ranges having a minimumvalue of equal to or greater than zero and a maximum value of equal toor less than 10, e.g., 1 to 5. In certain cases, the numerical values asstated for the parameter can take on negative values. In this case, theexample value of range stated as “less than 10” can assume negativevalues, e.g. −1, −2, −3, −10, −20, −30, etc.

While the present teachings have been illustrated with respect to one ormore implementations, alterations and/or modifications can be made tothe illustrated examples without departing from the spirit and scope ofthe appended claims. For example, it will be appreciated that while theprocess is described as a series of acts or events, the presentteachings are not limited by the ordering of such acts or events. Someacts may occur in different orders and/or concurrently with other actsor events apart from those described herein. Also, not all processstages may be required to implement a methodology in accordance with oneor more aspects or embodiments of the present teachings. It will beappreciated that structural components and/or processing stages can beadded or existing structural components and/or processing stages can beremoved or modified. Further, one or more of the acts depicted hereinmay be carried out in one or more separate acts and/or phases.Furthermore, to the extent that the terms “including,” “includes,”“having,” “has,” “with,” or variants thereof are used in either thedetailed description and the claims, such terms are intended to beinclusive in a manner similar to the term “comprising.” The term “atleast one of” is used to mean one or more of the listed items can beselected. As used herein, the term “one or more of” with respect to alisting of items such as, for example, A and B, means A alone, B alone,or A and B. The term “at least one of” is used to mean one or more ofthe listed items can be selected. Further, in the discussion and claimsherein, the term “on” used with respect to two materials, one “on” theother, means at least some contact between the materials, while “over”means the materials are in proximity, but possibly with one or moreadditional intervening materials such that contact is possible but notrequired. Neither “on” nor “over” implies any directionality as usedherein. The term “conformal” describes a coating material in whichangles of the underlying material are preserved by the conformalmaterial. The term “about” indicates that the value listed may besomewhat altered, as long as the alteration does not result innonconformance of the process or structure to the illustratedembodiment. Finally, “exemplary” indicates the description is used as anexample, rather than implying that it is an ideal. Other embodiments ofthe present teachings will be apparent to those skilled in the art fromconsideration of the specification and practice of the disclosureherein. It is intended that the specification and examples be consideredas exemplary only, with a true scope and spirit of the present teachingsbeing indicated by the following claims.

Terms of relative position as used in this application are defined basedon a plane parallel to the conventional plane or working surface of aworkpiece, regardless of the orientation of the workpiece. The term“horizontal” or “lateral” as used in this application is defined as aplane parallel to the conventional plane or working surface of aworkpiece, regardless of the orientation of the workpiece. The term“vertical” refers to a direction perpendicular to the horizontal. Termssuch as “on,” “side” (as in “sidewall”), “higher,” “lower,” “over,”“top,” and “under” are defined with respect to the conventional plane orworking surface being on the top surface of the workpiece, regardless ofthe orientation of the workpiece.

The invention claimed is:
 1. A method for processing an article throughan application of heat, comprising: positioning a first smart susceptorheater blanket comprising a first wire ribbon adjacent to a second smartsusceptor heater blanket comprising a second wire ribbon; placing aplurality of uncured composite plies in proximity to the first smartsusceptor heater blanket and the second smart susceptor heater blanket;applying a current to a plurality of first wire assemblies of the firstwire ribbon, wherein each first wire assembly is adjacent to at leastone other first wire assembly, such that a current flow through eachfirst wire assembly is in a direction that is opposite to a current flowthrough any adjacent first wire assembly; and applying a current to aplurality of second wire assemblies of the second wire ribbon such thata current flow through each second wire assembly is in a direction thatis opposite to a current flow through any adjacent second wire assembly,wherein: each second wire assembly is adjacent to at least one othersecond wire assembly; and the positioning further comprises placing thefirst smart susceptor heater blanket adjacent to one of the second wireassemblies such that the current flow through the first wire assemblyadjacent to the second wire assembly is in a direction that is oppositeto the current flow through the adjacent second wire assembly.
 2. Themethod of claim 1, wherein the applying of the current to the pluralityof first wire assemblies and the applying of the current to theplurality of second wire assemblies applies the current in seriesbetween the first smart susceptor heater blanket and the second smartsusceptor heater blanket.
 3. The method of claim 1, wherein the applyingof the current to the plurality of first wire assemblies and theapplying of the current to the plurality of second wire assembliesapplies the current in parallel between the first smart susceptor heaterblanket and the second smart susceptor heater blanket.
 4. The method ofclaim 3, further comprising: applying the current flow to the pluralityof first wire assemblies using a first power supply; and applying thecurrent flow to the plurality of second wire assemblies using a secondpower supply.
 5. The method of claim 4, further comprising: regulatingthe current flow to the first smart susceptor heater blanket using acontroller; and regulating the current flow to the second smartsusceptor heater blanket using the controller.
 6. The method of claim 5,further comprising: monitoring a plurality of temperatures at aplurality of locations of the first smart susceptor heater blanket usinga first plurality of thermal sensors distributed across the first smartsusceptor heater blanket; regulating the current flow output by thefirst power supply to the first smart susceptor heater blanket based onan output received from the first plurality of thermal sensors using thecontroller; monitoring a plurality of temperatures at a plurality oflocations of the second smart susceptor heater blanket using a secondplurality of thermal sensors distributed across the second smartsusceptor heater blanket; and regulating the current flow output by thesecond power supply to the second smart susceptor heater blanket basedon an output received from the second plurality of thermal sensors usingthe controller.
 7. The method of claim 1, further comprising:transmitting an output from a first plurality of thermal sensorsdistributed across the first smart susceptor heater blanket to acontroller; transmitting an output from a second plurality of thermalsensors distributed across the second smart susceptor heater blanket tothe controller; regulating the current flow to the second smartsusceptor heater blanket based on the output from the first plurality ofthermal sensors using the controller; and regulating the current flow tothe first smart susceptor heater blanket based on the output from thesecond plurality of thermal sensors using the controller.
 8. The methodof claim 7, wherein the controller is a master controller and the methodfurther comprises: controlling a first slave controller using the mastercontroller to perform the regulating of the current flow to the firstsmart susceptor heater blanket; and controlling a second slavecontroller using the master controller to perform the regulating of thecurrent flow to the second smart susceptor heater blanket.
 9. The methodof claim 1, further comprising: placing a plurality of composite pliesinto a vacuum bag, wherein the plurality of composite plies arepre-impregnated with an uncured resin; placing the vacuum bag and theplurality of composite plies in proximity to the first smart susceptorheater blanket and the second smart susceptor heater blanket; andheating the plurality of composite plies using the first smart susceptorheater blanket and the second smart susceptor heater blanket.
 10. Themethod of claim 9, further comprising applying a vacuum to the vacuumbag and to the plurality of composite plies during the heating to debulkthe plurality of composite plies.
 11. A method for debulking an aircraftcomponent, comprising: positioning an uncured composite laminatecomprising a plurality of prepregs onto a layup mandrel; positioning aheater blanket assembly adjacent to the uncured composite laminate,wherein the heater blanket assembly comprises a first smart susceptorheater blanket comprising a first wire ribbon adjacent to a second smartsusceptor heater blanket comprising a second wire ribbon; applying acurrent to a plurality of first wire assemblies of the first wireribbon, wherein each first wire assembly is adjacent to at least oneother first wire assembly, such that a current flow through each firstwire assembly is in a direction that is opposite to a current flowthrough any other adjacent first wire assembly; applying a current to aplurality of second wire assemblies of the second wire ribbon such thata current flow through each second wire assembly is in a direction thatis opposite to a current flow through any other adjacent second wireassembly, wherein: each second wire assembly is adjacent to at least oneother second wire assembly; one of the second wire assemblies isadjacent to one of the first wire assemblies; and a current flow throughthe second wire assembly adjacent to the first wire assembly is in adirection that is opposite to the current flow through the adjacentfirst wire assembly; and heating the uncured composite laminate usingthe heater blanket assembly.
 12. The method of claim 11, furthercomprising applying a vacuum to the uncured composite laminate duringthe heating of the uncured composite laminate.
 13. The method of claim12, further comprising: heating the uncured composite laminate to atemperature that is below a cure temperature of the uncured compositelaminate during the applying of the vacuum to the uncured compositelaminate, thereby debulking the uncured composite laminate; and removingthe debulked uncured composite laminate from the layup mandrel prior tothe uncured composite laminate reaching a cure temperature of theuncured composite laminate.
 14. The method of claim 11, furthercomprising: applying the current flow to the plurality of first wireassemblies using a first power supply; and applying the current flow tothe plurality of second wire assemblies using a second power supply. 15.The method of claim 14, further comprising: regulating the current flowto the first smart susceptor heater blanket using a controller; andregulating the current flow to the second smart susceptor heater blanketusing the controller.
 16. The method of claim 15, further comprising:monitoring a plurality of temperatures at a plurality of locations ofthe first smart susceptor heater blanket using a first plurality ofthermal sensors distributed across the first smart susceptor heaterblanket; regulating the current flow output by the first power supply tothe first smart susceptor heater blanket based on an output receivedfrom the first plurality of thermal sensors using the controller;monitoring a plurality of temperatures at a plurality of locations ofthe second smart susceptor heater blanket using a second plurality ofthermal sensors distributed across the second smart susceptor heaterblanket; and regulating the current flow output by the second powersupply to the second smart susceptor heater blanket based on an outputreceived from the second plurality of thermal sensors using thecontroller.
 17. The method of claim 11, further comprising: transmittingan output from a first plurality of thermal sensors distributed acrossthe first smart susceptor heater blanket to a controller; transmittingan output from a second plurality of thermal sensors distributed acrossthe second smart susceptor heater blanket to the controller; regulatingthe current flow to the second smart susceptor heater blanket based onthe output from the first plurality of thermal sensors using thecontroller; and regulating the current flow to the first smart susceptorheater blanket based on the output from the second plurality of thermalsensors using the controller.
 18. The method of claim 17, wherein thecontroller is a master controller and the method further comprises:controlling a first slave controller using the master controller toperform the regulating of the current flow to the first smart susceptorheater blanket; and controlling a second slave controller using themaster controller to perform the regulating of the current flow to thesecond smart susceptor heater blanket.
 19. The method of claim 11,further comprising: placing the uncured composite laminate into a vacuumbag; placing the vacuum bag and the uncured composite laminate onto thelayup mandrel; and heating the vacuum bag and the uncured compositelaminate using the first smart susceptor heater blanket and the secondsmart susceptor heater blanket.
 20. The method of claim 19, furthercomprising applying a vacuum to the vacuum bag and to the uncuredcomposite laminate during the heating to debulk the uncured compositelaminate.